Single flanged end ball valve of unitary construction

ABSTRACT

A ball valve unit for shutting off the flow of fluids flowing in heating and plumbing systems. The ball valve unit includes a ball valve and a main section including a flange formed integrally with the main section. A chamber is formed in the main section for receiving the ball of the ball valve. The main section is made of brass in order to prevent galvanic action between ball valve unit and the heating/plumbing system.

CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This Patent Application claims priority from U.S. ProvisionalPatent Application Serial No. 60/300,345, filed on Jun. 22, 2001 andU.S. Provisional Patent Application Serial No. 60/300,622, filed on Jun.25, 2001, the contents of which are incorporated herein by reference inits entirety.

BACKGROUND

[0002] This invention relates generally to ball valves, and moreparticularly to a flanged end ball valve of unitary construction.

[0003] Traditionally, a ball valve is used in plumbing and heatingapplications to shut off the flow of water or other fluid duringreplacement or repair of an in-line appliance or piece of equipment,such as a circulating pump. As shown in FIG. 1, typically, a ball valveused in a plumbing and heating application includes a separate flange 2,a conventional ball valve 4, and a copper nipple 6 and copper adapter 8that connect the flange 2 to the conventional ball valve 4. The ballvalve 4 is attached to the plumbing or heating system with copper tubing10. The in-line appliance (not shown) is attached to the flange 2.Alternatively, an iron nipple 12 has been used to connect the flange 2to the ball valve 4, and a copper adapter 14 has been used to connectthe ball valve 4 to the copper tubing 10, as shown in FIG. 2.

[0004] As shown in FIGS. 1 and 2, in the conventional methods, there areseveral potential leak paths. Also, there are areas of galvanic actionbetween dissimilar metals. Further, installation of the flange, thenipples, and the adapters in this type of configuration is timeconsuming and expensive.

[0005] The conventional method shown in FIG. 3 includes an iron flange16 that includes a screwdriver slot ball valve. The flange 16 isconnected to a second iron flange 18. A copper adapter 20 connects theiron flange 18 to copper tubing 10. In this configuration, since theflange 18 is made of iron, there is an area of galvanic action betweenthe iron flange 18 and the copper adapter 20. Also, there are severalpotential leak paths. Further, this configuration is complex, whichincreases the cost and installation time.

[0006]FIG. 4 shows another conventional configuration. Thisconfiguration includes an iron flange 30 connected to a copper tube 32via a copper adapter 34. In this conventional configuration, it is notpossible to isolate an in-line appliance, thereby making repair andreplacement of the in-line appliance burdensome. Also, there are severalpotential leak paths. Further, there are areas of galvanic actionbetween the copper adapter 34 and the iron flange 30.

SUMMARY OF THE INVENTION

[0007] The present invention provides a ball valve unit that reduces thecost and time required to replace in-line appliances such as pumps.

[0008] The ball valve unit of the present invention also reduces thenumber of joints and flanges, thereby reducing the volume of theplumbing system and the number of leakage paths.

[0009] Further, the present invention also provides a ball valve unitthat prevents the cracking of brittle iron flanges and prevents galvanicaction.

[0010] The present invention comprises a main section, a flange forconnecting the ball valve unit to an appliance, wherein the flange isintegrally formed with the main section, a ball valve, a chamber formedin the main section for accommodating the ball of the ball valve, and ahandle for actuating the ball valve.

BRIEF DESCRIPTION OF THE DRAWINGS

[0011] The foregoing and other features and advantages of the presentinvention will be more fully understood from the following detaileddescription of illustrative embodiments, taken in conjunction with theaccompanying drawings in which:

[0012]FIG. 1 shows a first conventional system.

[0013]FIG. 2 shows a second conventional system.

[0014]FIG. 3 shows a third conventional system.

[0015]FIG. 4 shows a fourth conventional system.

[0016]FIGS. 5A and 5B show cross-sectional views of one embodiment ofthe ball valve unit of the present invention.

[0017]FIGS. 6A and 6B show cross-section views of a second embodiment ofthe ball valve unit of the present invention.

[0018]FIGS. 7A and 7B show a third embodiment of the ball valve unit ofthe present invention.

[0019]FIGS. 8A and 8B show a fourth embodiment of the ball valve unit ofthe present invention.

[0020]FIGS. 9A and 9B show a fifth embodiment of the ball valve unit ofthe present invention.

[0021]FIGS. 10A and 10B show a sixth embodiment of the ball valve unitof the present invention.

DETAILED DESCRIPTION OF THE INVENTION

[0022]FIG. 5A shows a cross-sectional view of one embodiment of thepresent invention. As shown in FIG. 5A, the single flanged ball valveunit, according to the present invention, is designated by referencenumber 50. It comprises a handle nut 52, a washer 54, a stem 56, a ball58, a body 60, a handle 62, a packing gland 64, seats 66, and a stemseal 68. The body 60 comprises a main section 70 and an end cap 72. Themain section 70 includes a chamber 74 adapted to accommodate the ball 58and seats 66, a stem hole 76 to receive the stem 56 and stem seal 68,and a flange 78 to be positioned juxtaposed an inline appliance orequipment, such as a circulating pump (not shown). The ball valve unit50, preferably, is 600 PSI rated for use with water, oil or gas. Theinner diameter of the chamber 74 is substantially equal to the innerdiameter of the end cap 72, thereby maximizing flow through the ballvalve unit. FIG. 5B shows a side view of the flange 78.

[0023] The main section 70 and flange 78 are of unitary construction andpreferably made from cast or hot forged brass. Since plumbing andheating systems typically comprise brass or copper tubing, this preventsthe occurrence of electrolysis and galvanic action at the junction ofthe ball valve unit and the system tubing. Also, brass is a much softeralloy than traditional iron used for the flanges currently on the marketthat often crack when slightly over tightened.

[0024] The ball 58 is preferably made of Brass/Hard Chrome Plate andfits between seats 66, preferably made from Teflon® or PTFE. The ball 58is actuated with a blow-out proof stem 56 preferably made of Brass (ASTMB124-C37700). The ball 58 is actuated with a handle 62, preferably madeof stamped steel with a vinyl coating.

[0025] The stem 56 is sealed with a stem seal 68, preferably made fromTeflon® or PTFE, and an adjustable packing gland 64, preferably Brass(ASTM B124-C37700).

[0026] The end cap 72, preferably Brass (ASTM B124-C37700), is athreaded NPT (National Pipe Thread) connection, a Sweat (copper tubing)connection or a PEX (Cross Link Polyethylene) connection. The end cap 72can be of varying sizes such as ½″, ¾″, 1″, 1¼″, 1½″ and 2″. The end cap72 can be an (NPT) ANSI BI.20.1 threaded end (½″-2″), an ANSI B16.18solder end (½″-2″), or a PEX insert end (½″-1″).

[0027] When the ball valve unit is installed, the flange 78 is boltedto, for example, an iron flange that is part of a circulating pump (notshown). A rubber gasket 82 (preferably made of neoprene) forms the sealbetween the two flanges. The rubber gasket can be part of the flange 78or the pump. The gasket stops two unlike metals from touching eachother, thus eliminating galvanic action. Preferably, the flange 78 issubstantially flat so that it will fit different size appliances. Theflange 78 is consistent in size to fit most manufacturers smaller sizedcirculating pumps. A preferred length and thickness of the flange is 4⅛″and ⅜″, respectively.

[0028]FIG. 6A shows a cross-section of a second embodiment of the ballvalve unit of the present invention. The second embodiment issubstantially similar to the first embodiment. As shown in FIG. 6A, thesecond embodiment includes a wing-shaped handle 90 to allow for easyactuation of the valve. FIG. 6B shows a side view of the flange 78.

[0029]FIGS. 7A and 7B show a third embodiment of the ball valve unit ofthe present invention. As shown in FIG. 7A, the ball valve unit 100includes similar components as the ball valve unit 50 of the firstembodiment. Specifically, the ball valve unit 100 comprises, inter alia,ball valve 102, main section 104, handle 106, end cap 108, and flange110. In addition, the ball valve unit 100 includes a drain valve 120.The drain valve 120 is used to drain the system in the vicinity of theball valve 102. The drain valve 120 comprises a ball valve 122 that isactuated by a handle 106. The ball valve 122 is housed in extensiontubing 126 that is fitted to the main section 104 of the ball valve unit100. A hose (not shown) can be attached to the extension tubing fordraining the system. The extension tubing 126 preferably is made fromcast or hot forged brass.

[0030]FIGS. 8A and 8B show a fourth embodiment of the ball valve unit ofthe present invention. The fourth embodiment is substantially similar tothe third embodiment and includes a wing-shaped handle 200, as shown inFIGS. 8A and 8B.

[0031]FIGS. 9A and 9B show a fifth embodiment of the ball valve unit ofthe present invention. The fifth embodiment is substantially similar tothe third embodiment. In the fifth embodiment, the drain valve 120positioned between the flange 110 and ball valve 102, as shown in FIGS.9A and 9B.

[0032]FIGS. 10A and 10B show a sixth embodiment of the ball valve unitof the present invention. The sixth embodiment is substantially similarto the fifth embodiment and includes a wing-shaped handle 300.

[0033] Table 1 shows preferred dimensions for the ball valve units shownin FIGS. 5A, 5B, 6A and 6B.

[0034] The present invention, without the addition of any additionalcomponents, can be used to quickly and easily replace plumbingcomponents and appliances such as pumps. The appliance can be changed bysimply closing the ball valves and loosening bolts in the flanges oneach side of the appliance. The appliance will then drop out and a newone can be placed back in, thereby minimizing installation problems.

[0035] Further, because the ball valve is formed integral with theflange, the number of joints is reduced, thereby reducing the volume ofthe system and the number of leak paths.

[0036] Although the invention has been described with respect to variousembodiments, it should be realized this invention is also capable of awide variety of further and other embodiments. For example, the handle62, 90, 106, 200, 300 can be a different type than those shown in FIGS.5A-10B. In addition to brass, the body 60 and main section 70 can bemade of any material that reduces galvanic action, for example, copper,PVC, or bronze. Also, in the embodiments shown in FIGS. 7A-10B, ableeder valve can be used in addition to, or in place of, the drainvalve.

What is claimed is:
 1. A ball valve unit comprising: a main sectionformed of a rigid material; a flange formed of said rigid material andas a continuous portion of said main section; a ball valve including aball; a chamber formed in said main section for accommodating said ballof said ball valve; and a handle for actuating said ball valve.
 2. Theball valve unit of claim 1, wherein said ball valve unit furtherincludes a gasket disposed adjacent to said flange for forming a sealbetween said flange and said appliance.
 3. The ball valve unit of claim1, wherein said main section is made of brass.
 4. The ball valve unit ofclaim 1, further including an end cap attached to said main section. 5.The ball valve unit of claim 4, wherein said main section and said endcap are made of brass.
 6. The ball valve unit of claim 1, wherein anoutside surface of said flange is substantially flat.
 7. The ball valveunit of claim 1, wherein said handle is wing-shaped.
 8. The ball valveunit of claim 4, wherein an inner diameter of said chamber issubstantially equal to an inner diameter of said end cap.
 9. A ballvalve unit comprising: a main section formed of a rigid material; aflange formed of said rigid material and as a continuous portion of saidmain section, wherein said flange is adaptable to receive a gasket; aball valve including a ball; a chamber formed in said main section foraccommodating said ball of said ball valve; and a handle for actuatingsaid ball valve.
 10. A ball valve unit comprising: a main section formedof a rigid material; a flange formed of said rigid material and as acontinuous portion of said main section, a ball valve including a ball;a chamber formed in said main section for accommodating said ball ofsaid ball valve; a handle for actuating said ball valve; and a drainvalve formed in said main section for draining said ball valve unit. 11.The ball valve unit of claim 10, wherein said drain valve is disposedbetween said flange and said ball valve.
 12. The ball valve unit ofclaim 10, wherein said main section is made of brass.
 13. The ball valveunit of claim 10, further including an end cap attached to said mainsection.
 14. The ball valve unit of claim 13, wherein said main sectionand said end cap are made of brass.
 15. The ball valve unit of claim 10,wherein an outside surface of said flange is substantially flat.
 16. Theball valve unit of claim 10, wherein said handle is wing-shaped.
 17. Theball valve unit of claim 13, wherein an inner diameter of said chamberis substantially equal to an inner diameter of said end cap.